Optical unit for a vehicular lamp

ABSTRACT

An optical unit includes: a heat sink that radiates heat from a light source; and a base portion including a reflector mounting section, a lens mounting section and a connecting section connecting the reflector mounting section and the lens mounting section. The base portion is configured such that the light from the light source is reflected by a reflector mounted onto the reflector mounting section and is incident onto a projection lens mounted onto the lens mounting section. The heat sink is exposed to a space surrounded by the lens mounting section, the connecting section and the reflector mounting section.

CROSS REFERENCE TO RELATED APPLICATION(S)

The present disclosure relates to the subject matters contained inJapanese Patent Application No. 2010-203728 filed on Sep. 10, 2010,Japanese Patent Application No. 2010-203729 filed on Sep. 10, 2010, andJapanese Patent Application No. 2010-209109 filed on Sep. 17, 2010,which are incorporated herein by reference in its entirety.

FIELD

An exemplary embodiment of the present invention relates to an opticalunit and, specifically, an optical unit for use in a vehicle lightingapparatus.

BACKGROUND

There is known an optical unit for use in a vehicle lighting apparatuswhich reflects the light from a light source such as a semiconductorlight emitting element by a reflector and radiates the reflected lightthrough a projection lens in front of a vehicle. In this optical unit,its base portion, on which the projection lens and reflector aremounted, is structured such that it is connected to a heat sinkincluding a portion for carrying thereon the semiconductor lightemitting element.

As shown in FIG. 6 of JP-A-2007-35547, for example, a first aspect ofthis related art optical unit, a shade corresponding to the base portionincludes a plane section disposed substantially horizontally and a bentsection situated forwardly of the plane section and bent downward so asnot to shield the light from the light source incident into theprojection lens. Further a fastening screw extending from the backsurface side of the heat sink and penetrating through the heat sink isthreadedly engaged with a female screw section formed on the backsurface side of the bent section, whereby the shade is mounted to theheat sink.

As shown in FIG. 6 of JP-A-2007-35547, for example, in a second aspectof this related art optical unit, the reflector is mounted through lanceengagement on a shade corresponding to a base portion. Specifically, theshade includes rectangular projecting sections respectively formed onthe right and left outer surfaces thereof, and the reflector includes,on the right and left outer surfaces thereof, hooks each having arectangular opening. The rectangular projecting sections arerespectively fitted into their associated rectangular openings of thehooks to thereby mount the reflector onto the shade.

As shown in FIG. 6 of JP-A-2007-35547, for example, in a third aspect ofthis related art optical unit, the shade corresponding to the baseportion is mounted onto the heat sink using the fastening screwpenetrating through the heat sink and extending from the back surfaceside thereof. Specifically, the shade includes a plane portion disposedsubstantially horizontally and a bent portion situated more forwardlythan the plane portion and bent downwardly so as not to shut off thelight from the light source incident onto the projection lens. Further,there is formed a female screw portion on the back surface side of thebent portion. The fastening screw extending from the back surface, sideof the heat sink is threadedly engaged with the female screw portion tothereby mount the shade onto the heat sink.

In the first aspect of the related optical unit, there is a possibilitythat the sunlight incident through the projection lens from outside canbe condensed near the bent section of the base portion to thereby raisethe temperature of the base portion. Generally, since the base portionis made of resin, the base portion can be deformed or melted when a hightemperature is caused. On the other hand, when the base portion isformed of highly heat-resisting material, for example, or when the bentsection is shifted backward in the optical axis direction and is therebymade distant from the condensing portion of the sunlight, thedeformation and melting damage of the base portion can be prevented.However, such sunlight concentration measures cause an increasedmanufacturing cost of the optical unit and an increased size thereof.

A first aspect of an exemplary embodiment of the present invention maysolve some of the above problems. Thus, it is a first object of anexemplary embodiment of the invention to provide a technology which,without causing increased manufacturing cost of the optical unit andincreased size, may avoid deformation or melted damage of the baseportion by the concentration of the sunlight.

As described in the second aspect of the related optical unit, in thestructure in which the reflector is mounted onto the base portionthrough lance engagement, when the hooks of the reflector are fittedinto the rectangular projecting sections of the base portion, thereflector is inevitably deformed. Specifically, when the hooks of thereflector are pressed against the rectangular projecting sections of thebase portion, the reflector is spread outwardly, while the front ends ofthe hooks are caused to move onto the rectangular projecting sections.When the front ends of the hooks climb over the rectangular projectingsections, the reflector is going to return its original shape, wherebythe rectangular projecting sections fit into the rectangular openings ofthe hooks. Also, in this structure, in a state where the rectangularprojecting sections fit in the rectangular openings of the hooks, theslightly outwardly spread state of the reflector is maintained. Bydeforming the reflector to spread outwardly, a reacting force capable ofsandwiching the base portion can be generated in the reflector and thusthe reflector can be fixed to the base portion due to such reactingforce.

In the case that the reflector is deformed in this manner when mountingthe reflector or after it has been mounted, there is a possibility thatthe reflection surface of the reflector can be deformed. When thereflection surface of the reflector is deformed, there is a fear that alight distribution pattern to be formed by a vehicle lighting apparatuscan also be deformed. Therefore, in order to enhance the formingaccuracy of the light distribution pattern, there is room forimprovement in the related structure.

A second aspect of an exemplary embodiment of the present invention maysolve the above problem. Thus, it is a second object of the invention toprovide an optical unit which can enhance the forming accuracy of thelight distribution pattern.

As described above in the third aspect of the related optical unit, inthe structure in which the base portion is mounted on the heat sink bythe fastening screw extending from the back surface side of the heatsink, the rear section of the base portion is connected to the heatsink. On the other hand, since a projection lens having a relativelylarge weight is mounted on the front end section of the base portion,the center of gravity of the base portion exists near the front sectionthereof. Therefore, the position of the connecting section forconnecting together the base portion and heat sink is distant from theposition of the center of gravity of the base portion. Thus, in order toenhance the rigidity of the optical unit against vibrations and shocksto be transmitted thereto while the vehicle is running, the relatedstructure has some room for improvement.

A third aspect of an exemplary embodiment of the present invention aimsat solving the above problems. Thus, it is a third object of theinvention to provide a technology which can enhance the rigidity of anoptical unit for use in a vehicle lighting apparatus.

SUMMARY

According to the first aspect of the invention, there is provided anoptical unit including: a heat sink that radiates heat from a lightsource; and a base portion including a reflector mounting section, alens mounting section and a connecting section connecting the reflectormounting section and the lens mounting section, wherein the base portionis configured such that the light from the light source is reflected bya reflector mounted onto the reflector mounting section and is incidentonto a projection lens mounted onto the lens mounting section, andwherein the heat sink is exposed to a space surrounded by the lensmounting section, the connecting section and the reflector mountingsection.

According to this aspect, it may be possible to avoid a fear that thebase portion of the optical unit can be deformed or melted and damagedby the concentration of the sunlight, without causing the increasedmanufacturing cost of the optical unit and the increased size thereof.

In the above aspect, the heat sink may extend more forward in an opticalaxis direction of the optical unit than a front end of the reflectormounting section and may pass below the reflector mounting section. Inthis case, when compared with a structure in which radiating fins areprovided only on the back surface side of the heat sink, the heatradiation property of the optical unit can be enhanced because theradiating fins can be provided at positions nearer to the light source.

In the above aspect, the heat sink may include a radiating fin, and theradiating fin might be viewable from outside the optical unit throughthe projection lens mounted on the lens mounting portion. In this case,the appearance of the optical unit can be innovative and thus the designof the optical unit can be enhanced.

In the above aspect, a front end of the reflector mounting portion mayform a shade for forming a cutoff line of a light distribution pattern.Even in this case, it may be possible to avoid a fear that the baseportion of the optical unit can be deformed or melted and damaged by theconcentration of the sunlight, without causing the increasedmanufacturing cost of the optical unit and the increased size thereof.

According to the second aspect of the invention, there is provided anoptical unit including: a reflector; a base portion including areflector placement surface; a fixing pin; and a pin hole provided inthe base portion at a position corresponding to the fixing pin, whereinthe reflector includes an opposite surface that faces the reflectorplacement surface, wherein the fixing pin is provided in the oppositesurface, and wherein the reflector is fixed to the base portion with thefixing pin inserted into the pin hole.

According to this aspect, there may be provided an optical unit whichcan enhance the forming accuracy of the light distribution pattern.

In the above aspect, the leading end portion of the fixing pin may alsoproject from the pin hole, and the portion of the fixing pin projectingfrom the pin hole may be welded to the base portion. In this case, thereflector and base portion can be fixed more positively.

In the above aspect, a butt section may be provided in at least one ofthe opposite surface and reflector placement surface. When the buttsection is provided in the opposite surface, the butt section maycontact with the reflector placement surface whereby the reflector andthe base portion are aligned with each other in a distance direction.When the butt section is provided in the reflector placement surface,the butt section may be contacted with the opposite surface whereby thereflector and the base portion may be aligned with each other in thedistance direction. In this case, the forming accuracy of the lightdistribution pattern might be further enhanced.

In the above aspect, the fixing pin may also include, in an area betweenthe opposite surface and the reflector placement surface, a portionhaving a larger diameter than a diameter of the pin hole. In this case,since only the leading end portion of the fixing pin located forward ofthe portion having a larger diameter than the pin hole can be insertedinto the pin hole, it might be possible to prevent the excessiveinsertion of the fixing pin into the pin hole and, consequently,deformation of the reflector may be prevented.

In the above aspect, the portion of the fixing pin having the largerdiameter than the diameter of the pin hole may also include a surfaceparallel to the reflector placement surface, and a space may be formedbetween the parallel surface and the reflector placement surface. Inthis case, when the reflector is pressed against the base portion, theportion of the fixing pin having a larger diameter than the pin hole canbe surface contacted with the reflector placement surface, and therebymay positively prevent the excessive insertion of the fixing pin intothe pin hole.

According to the third aspect of the invention, there is provided anoptical unit for use in a vehicle lighting apparatus, the optical unitincluding: a heat sink that radiates heat from a light source; a baseportion including a reflector mounting section, a lens mounting sectionand a connecting section connecting the reflector mounting section andthe lens mounting section; and a connecting mechanism between the heatsink and the base portion, wherein the base portion is configured suchthat light from the light source is reflected by a reflector mountedonto the reflector mounting section and is incident onto a projectionlens mounted onto the lens mounting section, wherein the heat sink hasan extension portion that extends more forward in an optical axisdirection of the optical unit than a front end of the reflector mountingsection and passes below the reflector mounting section, and wherein theconnecting mechanism connects the connecting section and the extensionportion.

According to this aspect, the rigidity of an optical unit for use in avehicle lighting apparatus can be enhanced.

In the above aspect, the connecting mechanism may also be provided at aposition where the connecting mechanism overlaps a projection lensmounted onto the lens mounting section when the optical unit is viewedfrom its front. In this case, the size of the optical unit may bereduced.

In the above aspect, the connecting mechanism may also includes a screwhaving a head portion, a screw insertion hole provided in the connectingsection, and a screw receiving section provided in the extensionsection, wherein the screw may be inserted through the screw insertionhole and is threadedly engaged with the screw receiving section, and theconnecting section may be put between the head portion and extensionsection. In this case, since radiating fins can also be provided in theback surface side portion of the screw receiving section of theextension section, the heat radiating property of the optical unit canbe enhanced.

In the above aspect, the connecting portion may also include multipleprojecting portions, which are respectively provided in a periphery ofthe screw insertion hole and which contact with and are compressed bythe head portion. At least one of the base portion and the heat sink mayinclude a butt section contactable with the other. At least one of theprojecting sections may also extend substantially perpendicular to astraight line passing through a center of the screw insertion hole and acenter of the butt section. In this case, since the amount of force ofthe screw head portion transmitted to the butt section to compress theprojecting sections can be increased, the heat sink and base portion canbe aligned with each other in the distance direction with high accuracy.

In the above aspect, the butt section may also be disposed in aperipheral edge of the screw insertion hole, and some of the projectingsections may also extend radially with respect to the center of thescrew insertion hole. In this case, it might be possible to prevent theforce of the screw head portion for pressing and compressing theprojection sections from being excessively transmitted to the buttsections disposed in the peripheral edge of the screw insertion hole.

According to the first aspect of the present invention, it may bepossible to avoid a fear that the base portion of the optical unit canbe deformed or melted and damaged by the concentration of the sunlight,without causing the increased manufacturing cost of the optical unit andthe increased size thereof.

According to the second aspect of the invention, it may be possible toprovide an optical unit which can enhance the forming accuracy of alight distribution pattern. According to the third aspect of theinvention, it may be possible to enhance the rigidity of an optical unitfor use in a vehicle lighting apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

A general configuration that implements the various features of theinvention will be described with reference to the drawings. The drawingsand the associated descriptions are provided to illustrate embodimentsof the invention and should not limit the scope of the invention.

FIG. 1 is a schematic partial section view of the internal structure ofa vehicle headlight apparatus serving as a vehicle lighting apparatusincluding an optical unit according to a first embodiment of theinvention.

FIG. 2 is a schematic perspective view of the optical unit according tothe first embodiment when viewed obliquely from above.

FIG. 3A is a schematic perspective view of a reflector when viewedobliquely from above, FIG. 3B is a schematic perspective view of thereflector when viewed obliquely from below, and FIG. 3C is a schematicperspective view of a fixing pin when viewed obliquely from below.

FIG. 4 is a schematic perspective view of a heat sink when viewedobliquely from above.

FIG. 5A is a schematic perspective view of the base portion of theoptical unit when viewed obliquely from above, and FIG. 5B is aschematic perspective view of the base portion when viewed obliquelyfrom below.

FIG. 6A is a schematic plan view of the vicinity of the connectingsection of the base portion, and FIG. 6B is a schematic section viewtaken along a VIB-VIB line shown in FIG. 6A.

FIG. 7 is an exploded perspective view of the optical unit.

FIG. 8A is a schematic perspective view of the base portion with thereflector and projection lens mounted thereon when viewed obliquely fromabove. FIG. 8B is a schematic perspective view of the base portion withthe reflector and projection lens mounted thereon when viewed obliquelyfrom below.

FIGS. 9A to 9C are respectively schematic views of the reflector andbase portion, explaining a method for mounting the reflector onto thebase portion.

FIG. 10 is a schematic perspective view, showing state in which the baseportion with the reflector and projection lens mounted thereon ismounted on the heat sink.

FIG. 11 is a schematic section view taken along a plane including thecenter axis of a screw in a state where the base portion is mounted onthe heat sink.

FIGS. 12A to 12F are respectively schematic views, explaining a methodfor mounting the base portion onto the heat sink.

FIG. 13 is a schematic front view of the optical unit according to thefirst embodiment.

FIG. 14 is a schematic plan view of the vicinity of the connectingsection of the base portion according to a modification.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Now, description will be given below of the invention using a suitableembodiment thereof with reference to the accompanying drawings. The sameor equivalent composing elements, members and processes shown in therespective drawings are given the same designations and thus theduplicate description thereof will be omitted accordingly. Also, theembodiment is an example of the invention but should not be used tolimit the invention; and thus, all characteristics and theircombinations described in the present embodiment are not always theessential elements of the invention.

First Embodiment

FIG. 1 is a schematic partial section view of the internal structure ofa vehicle headlight apparatus serving as a vehicle lighting apparatusincluding an optical unit according to a first embodiment of theinvention. FIG. 2 is a schematic perspective view of the optical unitaccording to the first embodiment when viewed obliquely from above.Here, the vehicle headlight apparatus includes a pair of symmetricallyformed headlight units. In the case that the vehicle headlight apparatusis mounted on a vehicle, one of the headlight units is provided in theleft front portion of the vehicle, while the other is provided in theright front portion of the vehicle. FIG. 1 shows the structure of eitherone of the right and left headlight units used as the vehicle headlightapparatus.

As shown in FIG. 1, a vehicle headlight apparatus 10 according to thepresent embodiment includes a lamp body 12 having an opening formed onthe front side of the vehicle, and a light transmission cover 14 mountedso as to cover the opening of the lamp body 12. The light transmissioncover 14 is made of resin or glass having a light transmissibleproperty. Within a lamp chamber 13 constituted of the lamp body 12 andlight transmission cover 14, there is stored an optical unit 100.

As shown in FIGS. 1 and 2, the optical unit 100 is an optical unit of aso called projector type for use in a vehicle lighting apparatus and,specifically, it includes a reflector 110, a heat sink 130 and a baseportion 150. Also, the optical unit 100 according to the presentembodiment is an optical unit capable of forming a low beam lightdistribution pattern. The optical unit 100 is disposed such that itsoptical axis extends in the longitudinal direction of the vehicle, whilethe optical unit 100 is connected to the lamp body 12.

The reflector 110 has a reflection surface 110 a used to reflect lightemitted from a light source module 200 (light source). The heat sink 130includes a light source carrying portion 132 on which the light sourcemodule 200 can be carried, an extension portion 134 extending from thefront surface of the light source carrying portion 132 forwardly in theoptical axis direction, and a radiating fin 135 provided in theextension portion 134. Also, the heat sink 130 further includes a backsurface portion 136 extending upwardly from the back surface uppersection of the light source carrying portion 132, and a radiating fin137 provided in the back surface portion 136. The base portion 150includes a reflector mounting section 152 having a reflector placementsurface 152 a, a lens mounting section 154 for mounting the projectionlens 102, and a connecting section 156 for connecting together thereflector mounting section 152 and lens mounting section 154.

The heat sink 130 functions as a support member for supporting thereflector 110 and base portion 150, while the base portion 150 with thereflector 110 mounted thereon is connected to the heat sink 130 by aconnecting mechanism 170. Also, the heat sink 130 includes two screwholes 138 respectively formed in the back surface lower section of thelight source carrying portion 132 and in the back surface of the backsurface portion 136, while an aiming screw 16 penetrating through thelamp body 12 and extending forward therefrom and a leveling shaft 18 arethreadedly engaged with their associated screw holes 138 respectively.In this manner, the heat sink 130 is mounted onto the lamp body 12,whereby the optical unit 100 is mounted onto the lamp body 12.

The leveling shaft 18 is connected to a leveling actuator 20. Thevehicle headlight apparatus 10 is structured such that the optical axisof the optical unit 100 can be adjusted in the horizontal direction andin the vertical direction by the aiming screw 16, leveling shaft 18 andleveling actuator 20.

Next, with reference to FIGS. 3A to 3C, FIG. 4, FIGS. 5A and 5B, andFIGS. 6A and B, description will be given below specifically of thestructures of the respective portions of the optical unit 100. FIG. 3Ais a schematic perspective view of a reflector when viewed obliquelyfrom above, FIG. 3B is a schematic perspective view of the reflectorwhen viewed obliquely from below, and FIG. 3C is a schematic perspectiveview of a fixing pin when viewed obliquely from below. FIG. 4 is aschematic perspective view of a heat sink when viewed obliquely fromabove. FIG. 5A is a schematic perspective view of the base portion whenviewed obliquely from above, and FIG. 5B is a schematic perspective viewof the base portion when viewed obliquely from below. FIG. 6A is aschematic plan view of the vicinity of the connecting section of thebase portion, and FIG. 6B is a schematic section view taken along theVIB-VIB line shown in FIG. 6A.

As shown in FIGS. 3A and B, the reflector 110 is a reflection memberincluding on the inside thereof the reflection surface 110 a which isconstituted of, for example, a portion of a spheroid. The reflector 110is disposed more backward of the vehicle than the projection lens 102 insuch a manner that the first focus of the reflection surface 110 a issituated in the vicinity of the light source module (see FIG. 1) and thesecond focus of the reflection surface 110 a is situated in the vicinityof the rear focus of the projection lens 102 (see FIG. 1).

The reflector 110 includes an opposite surface 112 which is allowed toface the reflector placement surface 152 a in a state where thereflector 110 is mounted on the reflector mounting section 152 of thebase portion 150. On the opposite surface 112, there are provided afixing pin 114 used to fix the reflector 110 and base portion 150, apositioning pin 116 used to determine the positions of the reflector 110and base portion 150 in the horizontal direction, and aprojection-shaped butt portion 118 used to determine the positions ofthe reflector 110 and base portion 150 in the distance direction(vertical direction). In this embodiment, the opposite surface 112extends substantially in the form of an elliptic arc and is disposedsuch that it has axial symmetry with the optical axis. Each of a fixingpin 114 and a positioning pin 116 are respectively provided both on theright and the left sides with the optical axis between the two sides. Apair of butt portions 118 is provided on both the right and the leftsides with the optical axis between the two sides. Of the two buttportions 118 on each side, one is disposed more forwardly with respectto the vehicle than the fixing pin 114 and positioning pin 116, whilethe other butt portion 118 is disposed more rearward with respect to thevehicle than the fixing pin 114 and positioning pin 116.

As shown in FIG. 3C, the fixing pin 114 has a large diameter portion 114a, which has a diameter larger than the diameter of a pin hole 158(which will be discussed later) formed in the base portion 150. Thelarge diameter portion 114 a is disposed at the base end portion of thefixing pin 114, that is, at a position where it can contact with theopposite surface 112. Also, the large diameter portion 114 a has aparallel surface 114 b. The parallel surface 114 b is a surface which isallowed to be parallel to the reflector placement surface 152 a when thereflector 110 is mounted on the reflector mounting section 152 of thebase portion 150. That is, the fixing pin 114 has on the side surfacethereof a step the diameter which is larger on the base end side thereofthan on the leading end side thereof. The base end side of the fixingpin 114 formed from the step provides the large diameter portion 114 a.Further, the parallel surface 114 b is provided by the surface thatconnects the side surface of the large diameter portion 114 a with theside surface of the fixing pin 114, and is nearer to the leading end ofthe fixing pin than the large diameter portion 114 a.

The height of the fixing pin 114 is greater than the thickness of thesection of the base portion 150 where the pin hole 158 is formed, i.e.,the length of the pin hole 158. Also, the height of the large diameterportion 114 a is set as the height which, in a state where the reflector110 is mounted on the reflector mounting section 152 of the base portion150, makes it possible to form a space between the parallel surface 114b and reflector placement surface 152 a.

The heat sink 130 is a member used to radiate the heat of the lightsource module 200. As shown in FIG. 4, the heat sink 130 includes alight source carrying portion 132 for carrying the light source module200 thereon. The light source carrying portion 132 has a substantiallycuboid-like shape (see FIGS. 1 and 2) and includes, on the upper surfacethereof, alight source carrying surface 132 a for carrying the lightsource module 200 thereon. On the side surface of the light sourcecarrying portion 132 facing forwardly of the vehicle, there is formed aflat-plate shaped extension section 134 which extends forwardly in theoptical axis direction up to the vicinity of the projection lens 102. Inthis extension section 134, its main surface extends substantiallyhorizontally; and, on the upwardly facing main surface, there areprovided multiple radiating fins 135 such that they are arranged in thevehicle right and left direction. The radiating fins 135 respectivelyextend in the vehicle longitudinal direction and the back surfaces ofthe fins are contacted with the side surface of the light sourcecarrying portion 132 that faces forwardly of the vehicle. Also, theheight of the upper surface of each radiating fin 135 is substantiallyequal to that of the upper surface of the light source carrying portion132. Further, the vehicle forward side of the fin 135 decreases inheight as it goes forwardly of the vehicle in order not to shut off thelight which is reflected by the reflector 110 and is guided toward theprojection lens 102.

The extension portion 134 includes, in the sections thereof existingmore outwardly in the vehicle right and left direction than theradiating fins 135, screw receiving sections 176 which constitute aconnecting mechanism 17 (which will be discussed later). The screwreceiving sections 176 are formed on both the right and left sides. Theextension portion 134 also includes, in the sections thereof existingmore rearward with respect to the vehicle than the screw receivingsections 176 formed in the vehicle right and left direction two endportions, positioning pins 140 which are used to determine the positionsof the heat sink 130 and base portion 150 in the horizontal direction.The positioning pins 140 are provided apiece on the right and leftsides.

The light source carrying portion 132 includes, in the side surfacethereof that faces reward with respect to the vehicle, a flat-plateshaped back surface section 136 which extends in the vehicle verticaldirection. The main surface of the back surface section 136 is disposedto face in the vehicle front and back directions. On the portion of themain surface that faces in the vehicle back direction, there areprovided multiple radiating fins 137 in such a manner that they arearranged in the vehicle right and left direction. Also, a screw hole 138into which the aiming screw 16 (see FIG. 1) can be threadedly engaged isformed in the portion of the main surface of the back surface section136 which faces rearward with respect to the vehicle. A screw hole 138into which the leveling shaft 18 (see FIG. 1) can be threadedly engagedis formed in the portion of the side surface of the light sourcecarrying portion 132 which faces reward with respect to the vehicle. Theheat sink 130, which is made of, for example, aluminum die castings,includes the light source carrying portion 132, extension section 134,radiating fins 135, back surface section 136, radiating fins 137, screwholes 138 and screw receiving sections 176 which are all formedintegrally with each other.

As shown in FIG. 1, for example, the light source module 200, includes asemiconductor light emitting element 202 such as a light emitting diode(LED), and a substrate 204 for supporting the semiconductor lightemitting element 202. The substrate 204 is a heat conductive insulatingsubstrate made of ceramic or the like. On the substrate 204, there isformed an electrode (not shown) which transmits power to thesemiconductor light emitting element 202. The light source module 200 iscarried on the light source carrying portion 132 in such a manner thatthe light emitting surface of the semiconductor light emitting element202 faces upwardly of the vehicle and the radiation axis of thesemiconductor light emitting element 202 extends substantially in thevehicle vertical direction.

The base portion 150 is a member used to support the reflector 110 andprojection lens 102 (see FIGS. 1 and 2). As shown in FIGS. 5A and 5B,the base portion 150 includes a reflector mounting section 152 having areflector placement surface 152 a. The reflector mounting section 152has a flat-plate-like shape and is disposed such that its main surfacefaces in the vehicle vertical direction, while the portion of the mainsurface which faces upwardly of the vehicle provides the reflectorplacement surface 152 a. Also, the front end portion 152 b of thereflector mounting portion 152 forms a shade which is used to form thecutoff line of the low beam light distribution pattern (lightdistribution pattern). Specifically, the shape of an edge, which isformed by the vehicle front-side side surface of the reflector mountingsection 152 and reflector placement surface 152 a, corresponds to theshape of the cutoff line of the low beam light distribution pattern. Thefront end section 152 b is disposed near the second focus of thereflection surface 110 a and the rear focus of the projection lens 102.

A connecting section 156 is connected to the two right and left endsections of the reflector mounting portion 152. The connecting section156 corresponds to a pair of arm portions which extend from thereflector mounting portion 152 toward the front of the vehicle and theleading ends of which support the lens mounting portion 154. The lensmounting section 154 is connected to the vehicle front side end portionof the connecting section 156, whereby the reflector mounting portion152 and lens mounting portion 154 are connected together. Also, in theconnecting section 156, there is formed a screw insertion hole 174forming a connecting mechanism 170 which will be discussed later.

The lens mounting section 154 is a member having a substantiallycylindrical shape. The connecting section 156 is connected to thesurface of the lens mounting section 154 which faces rearward withrespect to the vehicle, the projection lens 102 is fixed to the surfacethereof which faces forward with respect to the vehicle. Multiple fixingpins 154 a which are used to fix the projection lens 102 are provided onthe surface of the lens mounting section 154, which faces forward withrespect to the vehicle.

The base portion 150 is structured such that, when it is mounted on theheat sink 130, the light of the light source module 200 can be reflectedby the reflector 110 mounted onto the reflector mounting section 152 andcan be then applied onto the projection lens 102 mounted onto the lensmounting section 154. Also, the base portion 150 is made of, forexample, resin, while the reflector mounting section 152, lens mountingsection 154 and connecting section 156 of the base portion 150 areformed integrally with each other.

The base portion 150 includes pin holes 158 into which the associatedfixing pins 114 can be inserted at positions corresponding to the fixingpins 114 provided on the reflector 110. The base portion 150 alsoincludes positioning holes 160 into which their associated positioningpins 116 can be inserted at the positions corresponding to thepositioning pins 116 provided on the reflector 110. In this embodiment,each of a pin hole 158 and a positioning hole 160 is formed on both thevehicle right and left sides end portions of the reflector mountingsection 152. Also, the reflector placement surface 152 a includes, atthe positions corresponding to the butt portions 118 of the reflector110, butt receiving portions 162 against which the associated buttportions 118 can be butted.

When the base portion 150 is mounted onto the heat sink 130, it contactsthe heat sink 130. Therefore, the base portion 150 includes multiplebutt portions 164 which are used to position the base portion 150 andheat sink 130 in the distance direction (in the vertical direction)thereof. The base portion 150 is carried on the heat sink 130 in such amanner that the vehicle lower side main surface of the reflectormounting section 152 faces the heat sink 130. Thus, in this embodiment,the reflector mounting section 152 includes, on the main surface thereofexisting on the lower side of the vehicle, projection-shaped buttportions 164 a; and, the connecting section 156 includes, on the surfacethereof facing downward with respect to the vehicle, projection-shapedbutt sections 164 b. Specifically, the butt sections 164 a are eachdisposed on one of the two end portions, in the vehicle width direction,of the vehicle downward side main surface of the reflector mountingsection 152. Also, the butt portions 164 b are disposed on theperipheral edges of the screw insertion holes 174 respectively formed onthe connecting section 156. Here, the butt portion 164 may preferably bedisposed on a line which passes through the screw insertion holes 174and extends in the vehicle front and back direction. Also, the baseportion 150 includes, at the positions thereof corresponding to thepositioning pins 140 provided on the heat sink 130, pin holes 166 intowhich their associated positioning pins 140 can be inserted.

As shown in FIGS. 6A and 6B, the connecting section 156 of the baseportion 150 includes multiple projecting sections 168 in the peripheryof the screw insertion holes 174. The multiple projecting sections 168are structured such that, when screws 172 respectively constituting aconnecting mechanism 170 (which will be discussed later) are threadedlyengaged with the screw receiving portions 176 of the heat sink 130inserted into the screw insertion holes 174, they contact the headportions of the screws 172 and thus can be compressed by them. In thisembodiment, each of the projecting sections 168 has a shape in which oneside surface of a triangular prism is in contact with the surface of itsassociated connecting section 156 and the top portion of the prismopposed to this side surface projects upwardly; Further each projectingsection 168 is structured such that, when the screw 172 is threadedlyengaged with the screw receiving portion 176, the upwardly projectingtop portion can be compressed.

Also, each of the multiple projecting sections 168 extends substantiallyperpendicularly to a straight line L which passes through the center Mof the screw insertion hole 174 and the center N of the butt section 164a disposed apart from the screw insertion hole 174. In other words, eachof the multiple projecting sections 168 is disposed such that the footportion thereof in contact with the upwardly projecting top portion andthe surface of the connecting section 156 extends substantiallyperpendicularly to the straight line L. Here, the above mentioned term“substantially perpendicularly” contains not only the case in which theprojecting section 168 extends perpendicularly to the straight line L,but also all shapes which can provide the below-mentioned operationeffect that the transmission amount of the pressing force of theprojecting section 168 against the butt section 164 a can be increased.

As shown in FIGS. 1 and 2, the projection lens 102 is made of aplano-convex aspherical lens the front side surface of which is a convexsurface and the back side surface of which is a plane. The projectionlens 102 is fixed to the lens mounting section 154 and is disposed onthe optical axis of the optical unit 100. The second focus of thereflection surface 110 a and the front end section 152 b of thereflector mounting section 152 are situated near the vicinity of therear focus of the projection lens 102. Further, the projection lens 102functions as an optical member which condenses the radiation light ofthe light source module 200 and projects it forwardly with respect tothe lighting apparatus.

Next, with reference to FIG. 7, FIGS. 8A and 8B, FIGS. 9A to 9C, FIG.10, FIG. 11, and FIGS. 12A to 12F, description will be given below ofthe assembly of the optical unit 100.

FIG. 7 is an exploded perspective view of the optical unit. FIG. 8A is aschematic perspective view of the base portion with the reflector andprojection lens attached when viewed obliquely from above, and FIG. 8Bis a schematic perspective view of the base portion with the reflectorand projection lens attached when viewed obliquely from below. FIGS. 9Ato 9C are schematic views of the reflector and base portionrespectively, and explain a method for mounting the reflector onto thebase portion. Specifically, FIG. 9A is a schematic side view of thevicinity of a fixing pin in a state where the reflector is attached tothe base portion, FIG. 9B is a schematic section view taken along aplane including the center axis of the fixing pin in the state shown inFIG. 9A, and FIG. 9C is a schematic section view to show a state wherethe leading end of the fixing pin is welded to the base portion. FIG. 10is a schematic perspective view, showing a state where the base portionwith the reflector and projection lens attached to the heat sink. Here,in FIG. 10, the illustration of the projection lens 102 is omitted. FIG.11 is a schematic section view taken along a plane including the centeraxis of a screw in a state where the base portion is attached to theheat sink. FIGS. 12A to 12F are respectively schematic views, explaininga method for attaching the base portion the heat sink. Specifically,FIGS. 12A to 12C show a state before they are screwed together, whileFIG. 12D to 12F show a state after they are screwed together. Morespecifically, FIGS. 12A and 12D are respectively schematic plan views ofthe vicinity of the connecting portion in the respective states, FIGS.12B and 12E are respectively schematic section views taken along a planeincluding the center axis of a screw insertion hole in the respectivestates, and FIGS. 12C and 12F are respectively schematic perspectiveviews when the vicinity of the connecting portion in the respectivestates is viewed obliquely from above. In FIG. 12D to 12F, theillustration of a screw is omitted.

As shown in FIG. 7, FIGS. 8A and 8B, the projection lens 102 is disposedon the vehicle front side of the base portion 150 in such a manner thatits plane faces the base portion 150. Further, while the fixing pin 154a of the lens mounting section 154 and the peripheral edge of theprojection lens 102 are aligned with each other, the projection lens 102is pressed against the lens mounting section 154. Thus, the projectionlens 102 is fixed to the lens mounting section 154. Also, the reflector110 is disposed upward of the reflector placement surface 152 a in sucha manner that the opposite surface 112 (see FIG. 3B) faces the reflectorplacement surface 152 a. Further, while the fixing pin 114 of thereflector 110 and the pin hole 158 of the base portion 150 are alignedwith each other and also the positioning pin 116 of the reflector 110and the positioning hole 160 of the base portion 150 are aligned witheach other, the reflector 110 is placed on the reflector placementsurface 152 a.

As shown in FIGS. 9A and 9B, when the reflector 110 is placed on thereflector placement surface 152 a, the fixing pin 114 is inserted intothe pin hole 158. The leading end portion of the fixing pin 114 insertedinto the pin hole 158 is projected from the pin hole 158 onto the backsurface side of the reflector placement surface 152 a. Also, thepositioning pin 116 is inserted into the positioning hole 160 (see FIG.7), thereby setting the positions of the reflector 110 and base portion150 in the front and back as well as right and left directions of thevehicle, i.e., in the horizontal direction. Also, the butt portions 118formed on the opposite surface 112 of the reflector 110 are contactedwith the butt receiving portions 162 of the reflector placement surface152 a, thereby setting the positions of the reflector 110 and baseportion 150 in the vehicle upward and downward direction, i.e., in thevertical direction (in the distance direction).

As shown in FIG. 9C, on the leading end portion of the fixing pin 114projecting from the pin hole 158, there is carried out, for example, aheat calking treatment, thereby deforming the leading end portion of thefixing pin 114, whereby there is formed a pin head portion 114 c thediameter of which is larger than the opening diameter of the pin hole158. The pin head portion 114 c prevents the reflector 110 from slippingoff from the base portion 150. In this embodiment, the base portion 150is placed on the seat of a heat calking apparatus and also, under agiven temperature condition, the reflector 110 is pressed toward thebase portion 150 with a given pressure. Due to this, the leading endportion of the fixing pin 114 projecting from the pin hole 158 is meltedand deformed to thereby form the pin head portion 114 c. The thus formedpin head portion 114 c is welded to the base portion 150.

Thus, in this embodiment, the fixing pin 114 is inserted into the pinhole 158, whereby the reflector 110 is fixed to the base portion 150.This can prevent the deformation of the reflector that is caused in arelated structure in which the reflector is mounted onto the baseportion using lance engagement. Consequently, the forming accuracy ofthe light distribution pattern can be enhanced. Also, in thisembodiment, since the fixing pin 114 is erected on the opposite surface112, when compared with a related structure in which the hook of a lanceengagement mechanism is provided on the outside surface of the reflector110, the outside dimension of the reflector 110 can be reduced. This canreduce the outside dimension of the optical unit 100 and the degree offreedom of design thereof.

Also, since the leading end portion of the fixing pin 114 is heat calkedand is thereby welded to the base portion 150, the reflector 110 andbase portion 150 can be fixed together firmly, thereby being able topositively prevent the reflector 110 from slipping off from the baseportion 150. Here, the method for fixing the reflector 110 to the baseportion 150 is not limited to the method for welding the leading endportion of the fixing pin 114 to the base portion 150. For example,there may also be employed a method for setting the diameter of thefixing pin 114 larger than the opening diameter of the pin hole 158 andpressure inserting the fixing pin 114 into the pin hole 158. Or, theabove methods may be combined together. Also, the above expression “thefixing pin 114 is inserted into the pin hole 158 and the reflector 110is thereby fixed to the base portion 150” includes a case where, as inthe heat calking treatment, the fixing pin 114 is deformed after it isinserted into the pin hole 158 to thereby fix together the reflector 110and base portion 150, and a case where, as in the pressure insertioncase, the insertion of the fixing pin 114 into the pin hole itselfcompletes the mutual fixing of the reflector 110 and base portion 150.In a case where the leading end portion of the fixing pin 114 is heatcalked, the reflector 110 is pressed toward the base portion 150. Due tothis, there is a fear that the portion of the reflector 110 existingbetween the two butt portions 118 can be flexed with the butt portion118 existing on the vehicle front side of the fixing pin 114 and thebutt portion 118 existing on the vehicle backside as the fulcrumsthereof and, consequently, the reflection surface 110 a can be deformed.On the other hand, the fixing pin 114 according to this embodiment, asshown in FIGS. 9B and 9C, includes, in a portion thereof which is storedwithin an area interposed between the opposite surface 112 and reflectorplacement surface 152 a, a large diameter portion 114 a having a largerdiameter than the pin hole 158. Therefore, only the portion of thefixing pin 114 existing nearer to the leading end portion than the largediameter portion 114 a can be inserted into the pin hole 158. This canprevent the excessive insertion of the fixing pin 114 into the pin hole158 and consequently deformation of the reflection surface 110 a. Thatis, since the insertion amount of the fixing pin 114 into the pin hole158 can be controlled, the deflection of the reflector 110 due topressure in the heat calking treatment can be reduced and thus thedeformation of the reflection surface 110 a can be avoided.

Also, the large diameter portion 114 a includes a parallel surface 114 bparallel to the reflector placement surface 152 a. Therefore, when thefixing pin 114 goes into the pin hole 158 and the large diameter portion114 a arrives at the reflector carrying surface 152 a, the parallelsurface 114 b and reflector placement surface 152 a are in surfacecontact with each other to thereby prevent the fixing pin 114 fromadvancing any further. Thus, the excessive insertion of the fixing pin114 into the pin hole 158 can be prevented more positively. Also, in astate after execution of the heat calking treatment on the fixing pin114, that is, in a state after the application of pressure to thereflector 110 and base portion 150 is removed, there is formed a space Hbetween the parallel surface 114 b and reflector placement surface 152a. Such formation of the space H between the parallel surface 114 b andreflector placement surface 152 a makes it possible to omit the highlyaccurate surface height control of the parallel surface 114 b, therebybeing able to prevent the complicated manufacturing process of the baseportion 150.

Next, as shown in FIGS. 7 and 10, the light source module 200 is carriedon the light source carrying portion 132 of the heat sink 130, wherebythe light source module 200 is fixed to the heat sink 130. Also, thebase portion 150 with the projection lens 102 and reflector 110 mountedthereon is disposed upward of the light source carrying portion 132 ofthe heat sink 130. Further, while the pin hole 166 of the base portion150 and the positioning pin 140 of the heat sink 130 are aligned witheach other, and the screw insertion hole 174 formed in the connectingsection 156 of the base portion 150 and the screw receiving section 176formed in the extension portion 134 of the heat sink 130 are alignedwith each other, the base portion 150 is placed onto the heat sink 130.Ina state where the base portion 150 is placed on the heat sink 130, thereflector mounting portion 152 contacts with the upper surface of thelight source carrying portion 132 which is exists more forward withrespect to the vehicle than the light source module 200 and the uppersurface of the radiating fin 135 which is rearward with respect to thevehicle. Also, the positioning pin 140 is inserted into the pin hole166, whereby the base portion 150 and heat sink 130 are aligned witheach other in the horizontal direction. Further, the butt sections 164 aand 164 b of the base portion 150 contact with the heat sink 130,whereby the base portion 150 and the heat sink 130 are aligned with eachother in the spacing direction (see FIG. 1). Further, the leading end ofthe screw receiving section 176 is inserted into the screw insertionhole 174.

Additionally, a screw 172 having a head portion 172 a is insertedthrough the screw insertion hole 174 and is thereby threadedly engagedwith the screw receiving section 176. Here, as shown in FIG. 11, theconnecting mechanism 170 for connecting the base portion 150 and heatsink 130 includes the screw 172 having the head portion 172 a, screwinsertion hole 174 formed in the connecting section 156 and screwreceiving section 176 formed in the extension portion. 134.Specifically, since the screw 172 is inserted through the screwinsertion hole 174 and is thereby threadedly engaged with the screwreceiving section 176, the connecting section 156 is sandwiched by thehead portion 172 a of the screw 172 and extension portion 134. Theconnecting mechanism 170 connects together with the connecting portion156 and extension portion 134 in this manner, thereby connectingtogether the base portion 150 and heat sink 130.

As shown in FIGS. 12A to 12C, the upper surface of the screw receivingsection 176 inserted into the screw insertion hole 174, before it isfastened by the screw 172, exists lower than the top part of theprojecting section 168. Additionally, the screw 172 is inserted into thescrew receiving section 176 until the lower surface of the head portion172 a contacts contacted the upper surface of the screw receivingsection 176 (see FIG. 11). As a result, the head portion. 172 a of thescrew 172 is pressed against the top part of the projecting section 168,which is upward of the upper surface of the screw receiving portion 176,whereby the connecting section 156 is pressed toward the extensionsection 134. Further, the butt section 164 of the connecting section 156is pressed against the heat sink 130 to thereby fix the base portion 150to the heat sink 130.

In this case, as shown in FIGS. 12D to 12F, the top part of theprojecting section 168, which is upward of the upper surface of thescrew receiving portion 176, is compressed and is thereby deformedplastically. Further, the force for compressing the projecting section168 is transmitted to the butt section 164 to thereby be able topositively press the butt section 164 against the heat sink 130. Thatis, the projecting section 168 functions as a compressing margin forfixing the base portion 150 to the heat sink 130.

The more distant the butt section 164 is from the contact portionbetween the screw 172 and projecting section 168, the harder the buttsection 164 is to receive the projecting section 168 compressing force.Therefore, the force to be transmitted to the butt section 164 adisposed distant from the connecting mechanism 170 is small whencompared with the butt section 164 b formed just below the area of theprojecting section 168. In view of this in this embodiment, theprojecting section 168 is formed such that it extends substantiallyperpendicularly to the straight line L passing through the center M ofthe screw insertion hole 174 and the center N of the butt section 164 a(see FIG. 6A). The force to press or compress the projecting section 168can be transmitted in a direction spreading from the top part of theprojecting section 168 toward the foot thereof. Therefore, the multipleprojecting sections 168 may be arranged such that the top and footportions thereof extend substantially perpendicular to the straight lineL, whereby the transmission directions of the pressing forces from therespective projecting sections 168 may be arranged toward the buttsections 164 a. This can increase the amount of the forces transmittedto the butt sections 164 a to press the projecting sections 168. Thus,the butt sections 164 a can be pressed against the heat sink 130 firmly,whereby the alignment between the heat sink 130 and base portion 150 inthe distance direction can be made more accurately.

Also, in this embodiment, the butt section 164 b is situated just belowthe contact portion between the screw 172 and projecting section 168.This allows the butt section 164 b to function as a base member, whichcan prevent deformation of the base portion 150 that might otherwise becaused when the connecting portion 156 is sandwiched by the head portion172 a of the screw 172 and extension section 134.

In the optical unit 100 structured such that the reflector 110, heatsink 130 and base portion 150 are assembled in the above-mentionedmanner, light emitted from the light source module 200 is reflected bythe reflection surface 110 a of the reflector 110, is allowed to passthrough the vicinity of the front end section 152 b of the reflectormounting section 152, and is then incident onto the projection lens 102.Light incident on the projection lens 102 is condensed by the projectionlens 102 and then radiated forward with respect to the vehicle. Thus, alow beam light distribution pattern can be formed in front of thevehicle.

As shown in FIGS. 2 and 10, in the optical unit 100 according to thisembodiment, the extension section 134 of the heat sink 130 passes belowthe reflector mounting section 152 and extends more forwardly in theoptical axis direction than the front end section 152 b of the reflectormounting section 152. Further, the extension section 134 is connected tothe connecting section 156 of the base portion 150 by the connectingmechanism 170. The center of gravity of the base portion 150 exists nearthe front portion of the vehicle because the projection lens 102 havingrelatively large mass is mounted on the front end portion of the baseportion 150. Therefore, a position for connecting together the baseportion and heat sink is distant from the center of gravity of the baseportion in a related structure in which a base portion is mounted onto aheat sink using a fastening screw extending from the back surface sideof the heat sink. On the other hand, in the optical unit 100 accordingto this embodiment, the base portion 150 and heat sink 130 are connectedtogether at a position nearer to the center of gravity of the baseportion 150 than the related structure. Therefore, when compared withthe related structure, the rigidity of the optical unit 100 with respectto vibrations and the like from outside can be enhanced.

Also, in the related structure, since the fastening screw is insertedinto the heat sink from the back surface side of the heat sink, aradiating fin cannot be disposed in the area of the heat sink into whichthe fastening screw is inserted. On the other hand, according to thisembodiment, since the connecting section 156 and extension section 134are connected together, when compared with the related structure, thenumber of radiating fins that can be provided on the back surface of theheat sink 130, or the areas of the respective radiating fins can beincreased. This can enhance the heat radiation property of the opticalunit 100 further.

Further, as described above, the extension section 134 of the heat sink130 passes below the reflector mounting section 152 and extends furtherforwardly than the front end section 152 b of the reflector mountingsection 152. Therefore, when compared with the related structure inwhich the radiating fins are provided only on the back surface side ofthe heat sink, the radiating fins 135 can be disposed nearer to thelight source module 200 and the number of radiating fins can beincreased. This can further enhance the heat radiation property of theoptical unit 100. Also, since providing the radiating fins 135 in theextension section 134 can reduce the number or area of radiating fins137 to be provided on the back surface section 136 side whilemaintaining the heat radiation property of the optical unit 100, thedimension of the optical unit 100 in the vehicle front and backdirections can be reduced.

Also, in the optical unit 100 according to this embodiment, theextension section 134 of the heat sink 130 is exposed to a spacesurrounded by the lens mounting section 154, connecting section 156 andreflector mounting section 152 of the base portion 150. In a relatedoptical unit, a base portion includes a plane section corresponding tothe reflector mounting section 152 and disposed substantiallyhorizontally, and a bent section situated more forwardly than the planesection and bent downwardly so as to not shut out the light of the lightsource incident onto a projection lens. In such related optical unit,sunlight incident through a projection lens is concentrated in thevicinity of the bent section of the base portion, thereby raising a fearthat the resin-made base portion can be deformed or melted and damaged.As a method for preventing the deformation or melting damage of the baseportion, there can be expected a method for forming the base portion ofmaterial having a high heat-resisting property, or a method for movingthe bent section backwardly in the optical axis direction to keep itaway from the sunlight concentrating portion. However, these methodsincrease the manufacturing cost and size of the optical unit. On theother hand, in the optical unit 100 according to this embodiment, theextension section 134 constituting a part of the heat sink 130 isexposed to the space surrounded by the lens mounting section 154,connecting section 156 and reflector mounting section 152. That is, theextension section 134 is disposed in the area where the bent section inthe related structure exists. Therefore, without increasing themanufacturing cost and size of the optical unit, there can be eliminatedthe fear that the base portion can be deformed or melted due to theconcentrated sunlight.

Generally, in order to enhance the utilization rate of the light of thelight source module, silver or the like is deposited on the base portionto enhance the light reflectance of the base portion. Thus, in therelated structure, there is a possibility that the light of the lightsource module outer-surface reflected by the incident surface of theprojection lens can be reflected by the bent section of the shade andcan be incident onto the projection lens, whereby the light can beradiated from the projection lens forward with respect to the vehicle.In the case that the light is reflected by the bent section and is thenradiated forward with respect to the vehicle, there is a possibilitythat it can be out of the radiation range of a light distributionpattern to be formed. This raises a fear that glare can be caused forother vehicles. On the other hand, in this embodiment, because there isdisposed the extension section 134 in the area where the bent section inthe related structure exists, it is possible to reduce the fear ofgiving glare to the other vehicles.

Also, in this embodiment, the screw insertion hole 174 is formed in thebase portion 150 and the screw receiving portion 176 is formed in theheat sink 130. Therefore, even in such section of the extension section134 as exists on the back surface side of the screw receiving portion176, there can be provided radiating fins. This can further enhance theheat radiation property of the optical unit 100.

FIG. 13 is a schematic front view of the optical unit according to thefirst embodiment. Here, in FIG. 13, the illustration of the projectionlens 102 is omitted. As shown in FIG. 13, in the optical unit 100according to this embodiment, the connecting mechanism 170 is situatedat a position where, when the optical unit 100 is viewed from the frontthereof, it is overlapped with the projection lens 102 mounted onto thelens mounting section 154. Further, in this embodiment, the center axisof the screw insertion hole 174 is situated further inward with respectto the vehicle width direction than the end section of the lens mountingsection 154 (see FIG. 10). Also, the connecting mechanism 170 isdisposed outside the area through which the light reflected by thereflection surface 110 a of the reflector 110 passes. Thus, the size ofthe optical unit 100 can be reduced because the connecting mechanism 170is disposed in the area in which it is has no influence on the formationof the light distribution pattern and it is overlapped by the projectionlens, when viewed from the front of the optical unit 100. Also, in theoptical unit 100 according to this embodiment, the radiating fins 135provided in the extension section 134 are seen from outside through theprojection lens to be mounted onto the lens mounting section 154.Therefore, the appearance of the optical unit 100 can be made novel andthus the quality of design of the optical unit 100 can be enhanced.

As has been described above, in the optical unit 100 according to thisembodiment, the reflector 110 includes the fixing pin 114 on theopposite surface 112, while the base portion 150 includes the pin hole158 at a position corresponding to the fixing pin 114. The fixing pin114 is inserted into the pin hole 158 to thereby fix the reflector 110to the base portion 150. Therefore, when compared with the relatedstructure where the reflector is mounted onto the base portion throughthe lance engagement, there can be reduced the fear that the reflector110 can be deformed. Thus, the forming accuracy of the lightdistribution pattern can be enhanced. Also, when compared with therelated structure using the lance engagement, the shapes of thereflector 110 and base portion 150 can be simplified and also theoutside dimension of the reflector 110 can be reduced.

Also, in the optical unit 100 according to this embodiment, the baseportion 150 includes the connecting section 156 for connecting togetherthe reflector mounting section 152 and lens mounting section 154, whilethe heat sink 130 includes the extension section 134 which passes belowthe reflector mounting section 152 and extends more forward in theoptical axis direction than the front end section 152 b of the reflectormounting section 152. The extension section 134 and connecting section156 are connected together by the connecting mechanism 170. Therefore,when compared with the related structure in which the base portion ismounted onto the heat sink using the fastening screw extending from theback surface side of the heat sink, the connecting position of the baseportion 150 and heat sink 130 can be made to approach the center ofgravity of the base portion 150. This can enhance the rigidity of theoptical unit 100.

Further, in the optical unit 100 according to this embodiment, theextension section 134 of the heat sink 130 is exposed to the spacesurrounded by the lens mounting section 154, connecting section 156 andreflector mounting section 152 of the base portion 150. This can preventsuch deformation and melting damage of the base portion due to theconcentration of the sunlight that can be possibly caused in the relatedstructure including a plane portion arranged substantially horizontallyand a bent portion existing forward of the plane portion and bentdownward in order to not to shut off the light from the light sourceincident onto the projection lens. Also, in the optical unit 100according to this embodiment, by disposing the extension section 134 ofthe heat sink 130 in the area where the bent portion is located in therelated structure, the base portion can be prevented against meltingdamage or the like. Therefore, when compared with a structure in whichthe bent portion is kept away from the concentrating portion of thesunlight, an increase in the manufacturing cost and size of the opticalunit 100 can be avoided.

The invention is not limited to the above-described embodiment butvarious modifications such as design change can also be added based onthe knowledge of a person skilled in the art. An embodiment with suchmodifications added thereto also falls within the scope of theinvention. A new embodiment provided by a combination of theabove-mentioned embodiment with the following modification provides bothof the effects that can be provided by the embodiment and modificationcombined.

FIG. 14 is a schematic plan view of the vicinity of the connectingsection of the base portion in an optical unit according to amodification. As shown in FIG. 14, in an optical unit 100 according tothe modification, a projecting portion 168, in part, extends radiallywith respect to the center M of a screw insertion hole 174, whereas theremaining portions thereof extend substantially perpendicularly to astraight line L. Specifically, a portion of the projecting portion 168located near a butt section 164 a extends substantially perpendicularlyto a straight line L, whereas the portion thereof that is distant fromthe butt section 164 a extends radially with respect to the center M. Inthis modification, the projecting sections 168, which have positions inthe vehicle front and back direction that are the same as the center Mof the screw insertion hole 174 or are situated rearward of the centerM, are set to intersect the straight line L substantially at rightangles, whereas the projecting sections 168 situated more forward withrespect to the vehicle than the center M are set to extend radially.

When the projecting sections 168 are disposed radially, the forces forpressing the projecting sections 168 by the screw 172 are easy totransmit in different directions in the respective projecting sections168, whereby the forces for pressing the projecting sections 168 can bediffused. Therefore, the amount of forces transmitted to press theprojecting sections 168 and to be transmitted to the butt sections 164can be reduced. On the other hand, since a butt section 164 b isdisposed in the peripheral edge of the screw insertion hole 174, thereis a fear that the force for pressing the projecting portion 168 couldbe excessively transmitted to the butt section 164 b. Therefore, in thismodification, the projecting sections 168 existing near the butt section164 a are disposed substantially perpendicular to the straight line L,thereby increasing the amount of the forces transmitted to press theprojecting sections 168 and transmitted to the butt section 164 a spacedapart from the contact portion between the screw 172 and projectingsection 168; Additionally, the projecting sections 168 existing in theother portions are arranged radially, thereby reducing the amount of theforces transmitted to press the projecting sections 168 and to betransmitted to the butt section 164 b formed just below the contactportion. This can eliminate the possibility that an excessive pressingforce can be applied to the extension section 134 through the buttportion 164 b. This can eliminate the fear that, when the base portion150 and heat sink 130 are connected together, the respective portionsthereof can be deformed or damaged. Thus, the yield of the optical unit100 can be enhanced.

Although, in the above embodiment, the fixing pin 114 is provided on theopposite surface 112 of the reflector 110 and the pinhole 158 is formedin the reflector placement surface 152 a of the base portion 150, thefixing pin 114 may also be provided on the reflector placement surface152 a and the pin hole 158 may be formed in the opposite surface 112.Also, although, the butt portion 118 is formed in the opposite surface112 in the above embodiment, the butt portion 118 may also be formed inthe reflector placement surface 152 a. In this case, the butt portion118 contacts with the opposite surface 112 to thereby align thereflector 110 and base portion 150 in the distance direction. Further,although, in the above embodiment, the butt section 164 is formed in thebase portion 150, the butt section 164 may also be formed in the heatsink 130.

In the above embodiment, the optical unit 100 is used to form the lowbeam light distribution pattern and the front end section 152 b of thereflector mounting section 152 constitutes a shade for forming thecutoff line of the low beam light distribution pattern. Alternatively,the optical unit 100 may also be structured such that it is used to forma high beam light distribution pattern and other light distributionpatterns.

In the above embodiment, in order to prevent the excessive insertion ofthe fixing pin 114 into the pin hole 158, the fixing pin 114 isstructured to include the large diameter portion 114 a. However, thestructure to prevent the excessive insertion of the fixing pin 114 intothe pin hole 158 is not specifically limited to this structure. Forexample, on the portion of the opposite surface 112 located in theperiphery of the fixing pin 114, there may be provided a projectingportion which projects toward the reflector placement surface 152 a.Alternatively, on the portion of the reflector placement surface 152 alocated in the periphery of the pin hole 158, there may be provided aprojecting portion projecting toward the opposite surface 112. Theheight of these projecting portions may be the same as the height, forexample, of the large diameter portion 114 a, i.e., the distance fromthe opposite surface 112 to the parallel surface 114 b. Also, theseprojecting portions may also have a top surface parallel to thereflector placement surface 152 a or the opposite surface 112 to whichthey are opposed. In these cases, when the fixing pin 114 is insertedinto the pin hole 158 and the reflector 110 is thereby pressed towardthe base portion 150, the projecting portions contact with the reflectorplacement surface 152 a or the opposite surface 112 to which they areopposed, thereby preventing the excessive insertion of the fixing pin114 into the pin hole 158. For example, the above-mentioned projectingportions respectively have a substantially rectangular shape when viewedfrom above and, specifically, one of them is disposed more forward withrespect to the vehicle than the pin hole 158, while the other isdisposed more reward with respect to the vehicle than the pin hole 158.Further, these two projecting portions are disposed such that theirlongitudinal directions are substantially parallel to the vehicle widthdirection.

1. An optical unit comprising: a heat sink that radiates heat from alight source; and a base portion including a reflector mounting section,a lens mounting section and a connecting section connecting thereflector mounting section and the lens mounting section, wherein thebase portion is configured such that light from the light source isreflected by a reflector mounted onto the reflector mounting section andis incident onto a projection lens mounted onto the lens mountingsection, and wherein the heat sink is exposed to a space surrounded bythe lens mounting section, the connecting section and the reflectormounting section.
 2. The optical unit of claim 1, wherein the heat sinkextends more forward in an optical axis direction of the optical unitthan a front end of the reflector mounting section and passes below thereflector mounting section.
 3. The optical unit of claim 1, wherein theheat sink includes a radiating fin, and the radiating fin is viewablefrom outside the optical unit through the projection lens mounted ontothe lens mounting section.
 4. The optical unit of claim 2, wherein theheat sink includes a radiating fin, and the radiating fin is viewablefrom outside the optical unit through the projection lens mounted ontothe lens mounting section.
 5. The optical unit of claim 1, wherein afront end of the reflector mounting section forms a shade for forming acutoff line of a light distribution pattern.
 6. The optical unit ofclaim 2, wherein a front end of the reflector mounting section forms ashade for forming a cutoff line of a light distribution pattern.
 7. Theoptical unit of claim 3, wherein a front end of the reflector mountingsection forms a shade for forming a cutoff line of a light distributionpattern.
 8. The optical unit of claim 4, wherein a front end of thereflector mounting section forms a shade for forming a cutoff line of alight distribution pattern. 9-20. (canceled)
 21. The optical unit ofclaim 1, wherein the heat sink extends to a vicinity of the projectionlens.
 22. The optical unit of claim 1, wherein the heat sink extends toa position at which sunlight being incident through the projection lensis concentrated.
 23. The optical unit of claim 21, wherein the heat sinkincludes an extension section that extends to the vicinity of theprojection lens, and wherein the heat sink includes a plurality ofradiating fins that: are disposed on a surface of the extension section,extend from the surface of the extension section in a directionintersecting the surface of the extension section, and are arrangedalong the surface of the extension section.
 24. The optical unit ofclaim 23, wherein the plurality of radiating fins extend upwardly fromthe surface of the extension section, and wherein the plurality ofradiating fins are arranged in a vehicle right and left direction. 25.The optical unit of claim 1, wherein the base portion further includesanother connecting section, wherein the connecting sections are disposedacross the light source, and wherein the heat sink is disposed betweenthe connecting sections.
 26. The optical unit of claim 25, wherein theconnecting sections are arranged in a vehicle right and left direction.27. An optical unit comprising: a heat sink that radiates heat from alight source; and a base portion including a reflector mounting section,a lens mounting section, and a connecting section connecting thereflector mounting section and the lens mounting section, wherein thebase portion is configured such that light from the light source isreflected by a reflector mounted onto the reflector mounting section andis incident onto a projection lens mounted onto the lens mountingsection, wherein the heat sink passes through an opening defined by thelens mounting section, the connecting section, and the reflectormounting section, and wherein the heat sink is a different member fromthe lens mounting section, the connecting section, and the reflectormounting section.
 28. The optical unit of claim 27, wherein the heatsink extends to a vicinity of the projection lens.
 29. The optical unitof claim 27, wherein the heat sink extends to a position at whichsunlight being incident through the projection lens is concentrated. 30.The optical unit of claim 28, the heat sink includes an extensionsection that extends to the vicinity of the projection lens, and theheat sink includes a plurality of radiating fins that: are disposed on asurface of the extension section, extend from the surface of theextension section in a direction intersecting the surface of theextension section, and are arranged along the surface of the extensionsection.
 31. The optical unit of claim 30, wherein the plurality ofradiating fins extend upwardly from the surface of the extensionsection, and wherein the plurality of radiating fins are arranged in avehicle right and left direction.
 32. The optical unit of claim 27,wherein the base portion further includes another connecting section,wherein the connecting sections are disposed across the light source,and wherein the heat sink is disposed between the connecting sections.